Method and apparatus for casting copper anodes



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March 28, 1939.

BUSCHE METHOD AND APPARATUS FOR CASTING COPPER ANO Filed MaylB, 1957[NVENTOR v Aida/pile Burr/1e ATTORNEY 35 anode and cathode surfaces.

so suit Patented a... 28, 1939 PATENT orrlce METHOD AND APPARATUS FORCASTING COPPER ANODES Adolphe Busche, Woodbridge, N. J., assignor toAmerican smelting and York, N. Y., a corporation of New Jersey RefiningCompany, New

I Application May 12, 1937, Serial No. 142,080

6 Claims.

In the production oi electrolytically refined copper, it is customary tocast the anodes to be refined by introducing the copper. into the anodemolds by meansof a ladle which receives the 5 copper directly from theanode furnace.

The anode molds are mounted customarily on some type of casting wheelwhich brings the molds successively under. the discharge of the ladlewhereby the copper flows from the ladle 10 into each successive mold forfilling the latter. The customary construction of the ladle provides foran end discharge of the copper from the ladle intothe mold beneath it,and, consequently, it is necessary to stop the rotation of the castingwheel 16 as the mold is filled thereby bringing each mold to a stopbeneath the discharge end of the ladle until the mold is filled. Whenthe mold'is filled, the wheel is actuated again until the next mold ofthe series is brought into filling position.

' g This intermittent operationof the. casting wheel and the end pouringof the copper from the ladle are opento decided disadvantages.

Thus, when the wheel is started after e ch mold is filled, the copper inthe mold is still molten or 25 plastic so that the. inertia of thecopper results in a tendency of the copper to surge against the side ofthe mold when the wheel is started thereby producing a rolled edge onthe cast anode.

The presence of such rolled edges acts to diminish, 3 very materially,the ampere efficiency of the refining cell,

it is impossible to obtain a positioning of the cathodes with respect tothe anodes so. as to have an equal distance between all portions of theWhere the, rolled edges are present on the anodes, the excess cop peralong such edges presents a less distance between such copper and thecathode surface than is present between the remaining portions A 40 ofthe electrode surfaces, so that there is a tendency to build up on thecathodes excrescences or projections of 'metal opposite to the rollededges of the anodes, which reduce the path of current travel from theanode to the cathode, tending to short circuit the cell and to increasegold and silver losses.

The elimination of such rolled edgeson the anodes becomes, therefore, avery desirable re- A further disadvantage of the usual practice ofcasting copper anodeslies in the fact that when the anodes are operatedso as to be stationary below the ladle, there maybe variations in thepouring time which hasan important eflecton because in the refiningoperations,

the application of the necessary mold dressing to the succeeding molds.

In this connection it is to be borne in mind that a mold wash is appliedto each mold before the copper is poured into the mold. The mold wash Icomprises usually a thin slurry of bone-ash, which slurry obviously isof a substantially constant density or specific gravity for each mold.

' The molds of course are hot, so that if there should be a substantialvariation in the pouring time for the molds as they reach pouringposition, the succeeding molds will have the mold dressing appliedthereto for varying periods of time before the molds are filled with thecopper. This may result in an insufilcient drying of the mold dressing,or an excessive drying thereof. The former condition is conducive totrouble upon the application of the copper to the mold, because of thepresence of moisture in the mold dressing or an inefiicient adherence oithe mold g dressing to the mold. When there has been excessive drying ofthe mold dressing, there is also a tendency of the dressing to separatefrom the mold because of caking or spelling of the dressing.

In either case there may be excessive inclusion of the molddressing inthe castings, or there may be difiiculty in discharging the castingsfrom the molds.

Aiurther disadvantage in the usual practice of discharging the copperfrom the end of the ladle into the anode molds lies in the fact that thecopper reaches the mold in a position which is towards what will be thebottom of the anode. Each mold is provided at what is to be the top ofthe anode with portions which define the contact lugs of the anodes whenthe latter are in operation in the refining cells. It is necessary tohave these lugs well formed in order for efficient contact to be madebetween the anodes and the bus-bars of the cells. This means that thepor- 40 tions of the mold which define the anode lugs should be wellfilled with copper and, accordingly, therefore, the copper should befully liquid when it flows into the lug recesses of the mold. In accordanee with the usual methods of casting, the

copper flows backwardly from the point of pouring which means it hasreached its lowest casting temperature when it is ready to flow intothese lugs. In order to have suflicient fluidity to fill these lugportions in a satisfactory manner, it is evident the copper must be wellsuperheated when placed in the mold.

This superheat, however, tends to produce a localized burning of themold where the stream of copper strikes the mold, the stream usuallybeing a The invention will required to start and to stop the castingwheel for each mold.

The present invention provides an improved method and apparatus forcasting copper anodesfor use in the production of electrolytic copper,which will obviate the above, and other, disadstopping of the castingwheel when each mold is to be nlled. In accordance with the presentinvention, the copper is poured into the molds from an improved type ofladle which enables the casting wheel to be. operated in a continuous,instead of in an intermittent, manner.

Further objects of the invention will become apparent as the descriptionproceeds and the features of novelty in the appended claims.

In accordance with the present invention, the copper is poured into themolds froma ladle which introduces the copper preferably as a pluralityof small streams, laterally of the mold, that is to'say in line with thedirection of travel of the molds Pouring the copper in .this mannerprevents localized burning :of the-molds and enables an eifectivecushioning action to be set up by the body of copper in the mold therebyfacilitating the production of anodes of uniform surface.

Furthermore, pouring the copper in this manher into the molds enablesthemolds to be.

without any breaki'n the operation of the wheel. so that the eifects ofinertia incident'to stopping and starting the wheel during casting withthe consequent productlonof the rolled edges referred to above.operation of the casting duce the proper mold for the production ofanodes of standard Furthermore thecontlnuouscperation of thecastingwheelpermihaclosecontmlofthetemperature of the molds, all moldsbeing at the same temperature when the application of the mold dressingwhereby .a uniform disposition and adherence of the mold dressing to themolds is obtained. and, all molds arrive at the pouring position at thesame temperature.

be understood more particularly by reference to the accom nying drawingwhich shows a dlagrammatical perspective view of the improved ladle andtilting mechanism therefor, the ladle being shown in position ready topour copper into the anode mold. Referring more particularly to thedrawing, the ladle comprises the metal receiving, or reservoir, portion2, which receives the metal from an anode furnace (not shown) and whichcommunicates with an elongated discharge launder extending over themolds longitudinally there of, one of the molds being indicated at 0.The mold I is understood to be one of a series of molds mounted on anyconventional type of easting wheel (not shown) so that the longitudinaldistribution will be pointed out in" detail on the cast anode, the smalll4 and It, and

. inder' 2|.

amoimt of copper. into each theyaresubiectedtoapproximately axis of themolds will extend radially of the casting wheel. In view lng' wheel isof any standard construction, it is not indicated on the drawing, thearrow 8 showing the. direction of travel of the molds.

The reservoir 2 of the ladle communicates through passage with thedischarge launder I, the latter being provided with a plurality oflaterally disposed discharge channels 36, which are distributed so as toavoid localization of impact of copper onto the mold but which areadapted to pour a plurality ofsmall streams of copper into the mold,which streams are'cushioned by the copper in the mold, splashing of thecopper being minimized thereby with attendant avoidance of the.formation of fins on the edge.of the cast anodes. Furthermore, the ofvcopper in the mold lssuch that of the fact that the castthe copper isfully fluid when it flows into the lug portions 38 of the mold therebyproducing well defined lugs for the anode which result in effectivecontact with the anode bus-bars during electrolysis of the anodes. Thenumber of channels for the discharge of-the copper is not, necessarily,a fixed number, this being determined by the particular operatingconditions.

In addition to preventing the formation of fins streams of coppeflowing" from the discharge channels 38 of the ladle prevent locoverheating and burning of the mold.

The reservoir portion I of the ladle is provided with a member It forattachment of a tilting cable II, which cable passes over sheaves of apiston rod ll, operating an hydraulic cyl- The flow of hydraulic fluidto the cylinder 28, is controlled by valve 22, which is operated by alever 24 in'the usual way, the fluid inlet and outlet lines for thevalve being lndi-' tilting mechanism, so thatcopper will flow from as aplurality of fine streams into the mold 0 thereby filling the latter.

It will be observed that the copper enters the mold inline with thedirection of travel of the moldas indicated by the arrow 8, and that thestreams of copper are mold. Since the time of pouring is proportioned tothe speed of movement or travel of the molds, the mold, which may be ofstandard size of approximately 36" x 36" x 1%" and holding 850 pounds ofcopper, may be filled without interruptlng the speed of travel of themold, sothat the mold will be illled with copper by the time it passesout from beneath the launder 4 of the ladle; whereupon the to stop theflow of copper from the launder until the succeeding mold reachespouring position,

casting wheel thereby being'continuously rotated throughout theoperation.

This continuous rotation of the wheel avoids the production of rollededges on the cast anodes due to the eil'ects ofinertia of the metalincident to starting and stopping the rotation of the easting wheel,thus assuring increased eilciency in which is connected to the end ladleis tilted backwardly.

well distributedover the the electrolytic refining more, the continuousoperation of the casting wheel means that the pouring time so thatthemold dressing is applied under con reservoir portion when the launderwhereby the said mold may be filled stant conditions to each empty moldprior to its reaching pouring position; and also there are pro-' ducedanodes of more uniform surface than have been obtainable uniformly bythe pouring pro,- cedure which has been regarded as standard practice,aspreviously outlined herein.

The tilting mechanism described above affords,

a means for proportion'ing the pouring rate to the rate of travel of themold so as to enable each mold to be filled launder 4 without mold.

What is claimed is: v

1. A ladle for introducing copper from an anode furnace into comprisinga reservoir portion, a launder portion extending from the reservoirportion over the mold and adapted to receive metal from the stopping themovement direction, mounting means for the ladle enabling the said ladleto be tilted laterally, laterally disposed discharge means and in thinstreams as the mold moves, beneath with metal while continuing itsmovement beneath the launder, and means for tilting'the mdle toinoperative position upon completion of the I filling of the mold.

adapted to. receive molten furnace, a launder communicating with thereserhaving a multiple spout adapted to discharge metal in thin streamsfilling position,

2. A ladle adapted for use in casting anodes for electrolytic refiningcomprising a reservoir portion metal from an anode voir portion, thesaid launder from the ladle into an anode mold laterally thereof withoutinterruption to the travel of the mold beneath the ladle as the moldreaches and means for tilting the ladle laterally between operative andinoperative positions relativeto the mold as the mold reachesand leavesfilling position.

3. A method of casting copper anodes for use which mode in theproduction of electrolytic copper comprises progressively moving aseries of a a aioneas of the anodes; furtheris constant, I

during its passage beneath the of the a series of traveling anode moldsthe ladle is tilted in one in the launder for distributing metal intothe mold laterally thereof.

molds into casting position a substantially uniform speed, filling themolds with copper by leading thereto molten copper from an anode furnacethrough a' suitable ladle and pouring. the copper from the ladle'lnaplurality of streams in line with the direction of travel of themold, and adjusting the pouring rate to the speed of travel of the moldsso as'to fill completely each mold with 4. Apparatus in the productionof electrolytic copper comprising the combination with a molds disposedfor able conveyor, of a ladle for supplying copper to the mold from amelting furnace, the said ladle 'comprising a multiple discharge spouthaving outlets adapted to deliver a'plurality of fine streams I ofcopper to'the mold in line with the direction of travel of the mold, thesaid outlets being arranged with;respect' to the mouldiso tribute thecopper uniformly in the mold as the mould moves beneath the ladle.

for casting copper anodes for use 5. Apparatus 'in the production ofelectrolytic copper which comprises the combination with-a plurality ofanode molds disposed for continuous travel on a suitable conveyor, of aladle for supplying copper to the mold from a melting furnace, allydirected discharge openings adapted to deliver a plurality of finestreams of copper to the mold longitudinally of the mold and distributeduniformly over the surface of the mold, and mechanism for controllingthe speed of delivery of copper from the ladle in accordance with therate of movementof the mold so in the rate of movement of the mold; v V

6, A process for casting copper anodes which comprises introducingcopper as a fine streams'into a continuously traveling 1 anode mold inmold, the said streams being he cushioned by copper already in themoldfor obviating splashing of the copper and formation 'of fins on theresulting cast anode.

as to disline with the direction of travel of the sufflciently fine tocopper without stopping the travel of the molds.

for casting copper anodes for useplurality of anode a continuous travelonv a suitthe said 1 ,ladle comprising a. discharge spout havinglaterthat the mold will become iilled with copper as it passes beneaththe said spout-without variation ,0 plurality of mourns suscnn.

